Extensible continuous haulage system

ABSTRACT

An extensible conveyor apparatus and method for a continuous haulage system and continuous conveyor belt are disclosed for carrying coal or ore discharged from a continuous miner. A top roller combination supports the coal-carrying or ore-carrying continuous conveyor belt. A holding frame for the top roller and a bottom belt return is provided by a plurality of floor-supported frame members held and secured in position by belt tension. The holding frame is capable of rapid and nimble extendable, retractable construction in the mine. Rails connect and hold adjacent frame members in position by press-fit attachment of the rails to the frame members. The rails preferably are quickly rotatable to change the top wearing surface. A top roller for supporting the mined-material-carrying belt includes a combination of rollers formed into a roller combination insert which is quickly replaceable in an underground mine.

This patent application is a continuation-in-part of prior, patent application U.S. Ser. No. 08/314,881 filed Sep. 29, 1994, now U.S. Pat No. 5,590,757, which was a continuation-in-part of Ser No. 08/125,598 filed Sep. 23, 1993, now U.S. Pat. No. 5,353,920.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to conveyor apparatus and method for use in mining operations. In one aspect, this invention relates to mining apparatus and method for performing continuous haulage in a mine.

2. Background Mining operations today use conveyor apparatus extensively to remove material, e.g., such as coal or ore, from the mine. The conveyor apparatus improves productivity over those methods which do not have "continuous" means for removing the mined material from the mine face.

U.S. Pat. No. 4,031,997, issued to Nelson, discloses a mobile cascade conveyor system, but nevertheless presents a background of the invention describing parallel room mining with intermittent/discontinuous or continuous methods for carrying coal from the continuous miner.

Continuous miner machines work at removing the mined material, e.g., ore or coal, from the mine face and thereby extend into the mine and away from the conveyor or other means for removing the material produced by the continuous miner. After the continuous miner extends so far, the miner must be retracted away from the mine face to install or construct roof supports. Accordingly, the mined material removal means, e.g., the conveyor apparatus, must be capable of extension and retraction in conjunction with movement of the continuous miner.

Conveyor apparatus available commercially today can be viewed as severely limited with respect to its flexibility and ease of operation in providing the extension and retractability for following the continuous miner. A new apparatus and method are needed to provide mined material removal for continuous haulage.

INTRODUCTION TO THE INVENTION

In the mining of coal, particularly but not limited to coal strip mines, many coal seams are exposed and/or identified which have a low vertical seam height. By low vertical seam height is meant less than standing room. The low coal seam vertical height makes it extremely difficult to impossible to recover the coal by conventional deep mining equipment and techniques. The low coal is left behind when the cover over the seam is too high to mine the coal by strip mining techniques. Moreover, since the vertical height of these coal seams is so low, it is extremely difficult, if not impossible, to mine the low coal with people in the shaft.

One technique which has developed to mine low coal is with the use of continuous mining equipment. A continuous miner works at the face of the low seam vertical height coal and separates the coal from the face of the mine. The coal produced from the continuous miner is passed preferably to a "continuous haulage" system for removal from the mine face, typically by passing through an extensible conveyor to a mainline conveyor for removal from the mine. By continuous haulage is meant the continuous transportation of the material mined from a continuous miner, from other mining machines, or from a production area to a main conveyor belt or belts leading to the surface or to a main terminal area where the mined material is processed.

U.S. Pat. No. 2,850,146, issued to Madeira, (hereinafter "Madeira") discloses a structure and technique considered to be the beginnings of low belt structure as it is known today. U.S. Pat. No. 2,850,146 discloses a portable conveyor for use in a coal mine represented to be simple in the setting up thereof, and also by ready portability in the mine or the like. An endless conveyor is provided having a pair of cables suspended as catenaries on spaced roof jacks. The endless conveyor belt is represented to be readily and easily disassembled and moved from one location to another location where the conveyor is easily reassembled. When positioned at the new location, it is extensible and retractable with a minimum amount of effort.

U.S. Pat. No. 2,850,146 discloses structure which is cable mounted, supported by roof jacks. A drawback of the cable-mounted system involves problems attributable to failure of suspension of the conveyor line when even just one roof jack loses its support. Loss of roof support is a problem which can and does occur, resulting in the cable structure losing its support.

The U.S. Pat. No. 2,850,146 patent utilizes rollers, and the structure disclosed in U.S. Pat. No. 2,850,146 is intended to be readily installed, but the actual structure design is deficient in the length of time actually needed to install it. The apparatus and methods disclosed in U.S. Pat. No. 2,850,146 are not designed to run continuous haulage because the Madeira conveyor does not form a track needed for the mobile bridge units extending from and attached to the continuous mining machine to tram or travel in order to form the continuous haulage system.

In underground mining, and particularly in but not limited to underground mining wherein the vertical work space affords less than standing room, physical tasks are made more difficult by the confined spaces and constraints imposed by the underground mine. Although the apparatus and method of the present invention are not intended to be limited by particular dimensions in a mine, physical movements and activity are made significantly more demanding in low seam mining, e.g., less than 48 inches in vertical height.

When conveyor apparatus is used in continuous haulage today to remove material from the mine, and when the conveyor apparatus is called upon to extend and retract in conjunction with the continuous miner, the conveyor must be repeatedly constructed and later broken down in the confining spaces and constraints within the mine. Conventional conveyor apparatus can be viewed as severely lacking in the areas of facilitating extension or retraction while accommodating the difficult physical activities found in the confining spaces or constraints in the underground mine. Novel apparatus and method are needed to facilitate rapid and flexible extension and retraction of the conveyor in the underground mine.

Conventional conveyor belts typically use idler rollers and/or roller bearings for carrying the main belt for hauling material on the endless conveyor belt. The idler rollers and/or roller bearings have difficult duty in the hostile environment of the mine. This hostile environment is attributable to water, corrosion, dust, or other hostile agents found in the mine. When the idler rollers or roller bearings need to be replaced, the load bearing surface typically undergoes a grinding operation by the belt as it passes. When the idler roller or roller bearing is ground to a sharp surface, the conveyor must be taken down to replace the belt.

The difficult duty of idler rollers or rollers containing roller bearings is made more acute with low vertical height mining because the rollers must be made of smaller diameter. The smaller diameter rollers must travel faster because of the higher number of revolutions per unit time. Accordingly, novel conveyor apparatus and method are needed to eliminate problems attributable to conventional idler rollers and other rollers using roller bearings.

U.S. Pat. No. 4,789,056, issued to Bourbeau, discloses a conveyor apparatus and method incorporating idler rollers such that when a load such as impact loads are placed on the conveyor belt, a slider bed supports the conveyor belt at the point where the material is loaded. This action in receiving the impact loads resists sagging and stretching of the conveyor belt and also reduces wear on the idler rollers. The idler rollers are mounted on a shaft and are adapted to be adjustable vertically depending on the load requirements. The conveyor belt system is modular and of unitary structure, and several modules can be joined to form a conveyor belt system of any designed length.

U.S. Pat. No. 4,215,776, issued to Esler, (hereinafter "Esler") discloses a belt conveyor idler having a ridged U-shaped channel fixedly mounted on a pair of spaced supports. A rigid strip of a low-friction material, such as high molecular weight polyethylene, is fixedly mounted within the channel and extends transversely across the path of the conveyor belt for slideably supporting the conveyor belt. The channel and strip of low-friction material each have a complimentary catenary configuration for the load-bearing troughing run of the conveyor belt and a straight horizontal configuration for the return run of the belt.

Conveyors such as the Esler conveyor will not work with continuous haulage systems. By continuous haulage is meant the uninterrupted transportation of material from a continuous miner unit to the mine transportation system by several units of haulage equipment and an associated continuous and advancing conveyor system.

The Esler conveyor also will not provide or facilitate the extension or retraction such that the conveyor can be put together and taken apart quickly and easily, particularly with confining spaces and constraints in an underground mine. Esler discloses belt conveyor idlers bolted onto end posts 5 bolted onto support channels 3 bolted onto suspension bracket 34.

U.S. Pat. No. 4,736,835, issued to Hinkle, (hereinafter "Hinkle") discloses a conveyor support frame incorporating a top bar "receiver" into which a top bar is inserted and rotated for the purpose of moving rigid locking elements of the top bars into a complex secure engagement with the receiver. Although Hinkle discloses a purpose to provide a quick release connection joint between support stands, the requirement in Hinkle to line up, turn, and lock the interlocking mechanism and receiver (and conversely to unlock, turn, and withdraw locking lugs 27 and 28 from jaw plate 20 for removal) is found to be difficult to operate in the confining spaces and in the muck and mire found typically in an underground mine. Further, the Hinkle locking lugs 27 and 28 of longitudinal bars 11 are locked into the receivers 18 and jaw plates 20 in such a way that they can only be inserted in one specific configuration, i.e., the top surfaces of the rails are not rotatably interchangeable.

Accordingly, new mining conveyor apparatus and method are needed to overcome the deficiencies found in conventional systems.

It is an object of the present invention to provide novel mining conveyor apparatus and method for a continuous haulage system.

It is another object of the present invention to provide an extensible mining conveyor apparatus and method capable of rapid and nimble extendable and retractable construction in a mine.

It is another object of the present invention to provide an extensible conveyor apparatus and method for providing a continuous conveyor belt for carrying coal or ore discharged from a continuous miner.

It is a further object of the present invention to provide an extensible conveyor apparatus having a holding frame capable of rapid and nimble construction and disassembly in the confining spaces and constraints of an underground mine.

It is a further object of the present invention to provide an extensible conveyor apparatus which reduces the conveyor drive motor requirements in size and amperage and which permits for longer runs of conveyor between conveyor drive motors.

SUMMARY OF THE INVENTION

The present invention provides an extensible conveyor apparatus and method for a continuous haulage system, including a continuous conveyor belt for carrying coal or ore discharged from a continuous miner, a top roller combination insert for supporting the coal-carrying or ore-carrying continuous conveyor belt, a bottom belt return, and a holding frame for holding the top roller combination insert, wherein the holding frame is provided by a plurality of floor-supported frame members held in position by belt tension, the holding frame being capable of rapid and nimble extendable, retractable construction in the mine.

The present invention includes rails for connecting and holding adjacent frame members in position by press-fit attachment of the rails to the frame members. The rails preferably are quickly rotatable to change the top wearing surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts the continuous mining operation in an underground mine by the room and pillar method and shows the tail piece and inboard or "inby" portion of the conveyor of the present invention.

FIG. 2 shows a perspective view of the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 3 shows a perspective view of the roller combination insert for the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 4 shows a section taken along Section A--A of FIG. 2 for the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 5 shows a section taken along Section B--B of FIG. 2 for the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 6 shows a perspective view of the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 7 shows a perspective view of an alternate embodiment for the roller combination insert for the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 8 shows a section taken along Section A--A of FIG. 6 for the novel extensible continuous haulage apparatus and method of the present invention.

FIG. 9 shows a section taken along Section B--B of FIG. 6 of the novel extensible continuous haulage apparatus and method of the present invention.

DETAILED DESCRIPTION

Referring now to FIG. 1, continuous miner 10 is shown operating in position at the mine face 12 in a room and pillar method of mining. FIG. 1 depicts the continuous mining operation in an underground mine by the room and pillar method and shows the tail piece and inboard or inby portion of the conveyor of the present invention. Coal is mined at the mine face 12 to form rooms with pillars 13 of coal remaining for support. Continuous miner 10 is operated to remove most of the vertical coal or ore from the seam and to leave just a very thin top and bottom layer of coal or ore behind. In this manner, the mined material is not contaminated with rock or other materials found vertically just adjacent to and outside a coal seam.

Continuous miner 10 removes material from the face 12 and transports and passes the material along bridges 16 and 17 to conveyor apparatus 20. Conveyor apparatus 20 has tail piece 21 and side rails 22 and 24. Coal from the continuous miner is typically passed along bridges 16 and 17 to be discharged onto conveyor 20. Conveyor 20 carries the mined material to a main conveyor (not shown) for carrying the mined material out of the mine.

FIG. 2 shows a perspective view of the novel extensible continuous haulage apparatus and method of the present invention.

Referring now to FIG. 2, conveyor 20 includes side rails 22 and 24 interconnected with holding frame 26 for holding top roller 27 and bottom belt return support 29. Holding frames 26 are floor-supported frame members.

Rails 22 and 24 slide onto pins attached to holding frame 26 as indicated by pins 28 for connecting rail 22 as shown in FIG. 2. Rail continuity insert 23 is positioned between ends of rail 22 or rail 24 to provide and maintain a continuity in the rail top surface for wheels (not shown) of a mobile bridge or other dolly or carriage to run on the top side of rail 22 or 24.

The rails 22 and 24 are provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24. By way of example, the rails can be round or square. An alignment brace 30 is provided to align the rail surfaces in the case when rails 22 and 24 are square and provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24. Alignment brace 30 also provides higher rigidity to holding frame 26 and facilitates the prevention of snaking of the extensible conveyor system of the present invention.

FIG. 3 shows a perspective view of the prefferred embodiment of the roller combination insert for the novel extensible continuous haulage apparatus and method of the present invention.

Referring now to FIG. 3, roller combination insert 27 has lateral, end portion rollers 31 and 33 positioned on either end of roller combination insert 27 and central or middle portion roller 35. Roller combination insert 27 is supported by, and connected to roller center shafts 10 (roller 31), 12 (roller 33), and 14 (roller 35). Rollers 31, 33, and 35 are held in combination by mechanical connectors represented by connectors 2 and 4. Mechanical connectors 2 and 4 are fabricated to permit shafts 10 and 12 to connect to center shaft 14 in a flexible, pivotal relationship. The flexible, pivotal relationship is automatically adjustable to conveyor width, and the depth of the conveyor trough thereby is controllably adjustable by predetermined specification of the roller combination insert 27.

The roller combination insert in the extensible haulage system of the present invention allows the mine operator to use motors and conveyor drive devices having significantly less power. The roller combination insert reduces the conveyor drive motor requirements in size and amperage. The roller combination insert also permits for longer runs of conveyor between conveyor drive motors.

The roller combination insert in the extensible haulage system of the present invention allows the mine operator to use larger conveyors and heavier belts, thereby to convey more massive amounts of mined material.

FIG. 4 shows the novel mining conveyor apparatus as viewed along Section A--A of FIG. 2.

Referring now to FIG. 4, top roller 27 is shown having a substantially horizontally disposed middle section 27a and upwardly turned end sections 27b to form a troughing or cupping angle greater than about 15° of troughing/cupping and, preferably, greater than about 20°. Most preferably, horizontally disposed middle section 27a and upwardly turned end sections 27b form a troughing or cupping angle, preferrably greater than about 27°.

Side rails 22 and 24 on opposite sides of the conveyor frame apparatus are shown having substantially equal angular sides and side dimensions so that the rails can be rotated to change the top surface as will be described in detail hereinbelow.

Bottom belt return support 29 preferably of a lightweight abrasion-resistant material supports the belt return for the endless belt conveyor system.

The wearing surface of top roller 27 can be replaced in the mine by removing top roller 27. A new lightweight top roller insert 27 can be fitted into and fastened into position by suitable fastener for connecting top roller insert 27 to holding frame 26 to install the new top roller 27 quickly in place in the mine.

The top roller 27 is formed such that it can be installed with any side (27b) on either of the holding stands 26. The top roller 27 thereby is interchangeable without regard to which side must be installed on a particular side of the holding support stand.

Top roller 27A is shown as it is to be built into the holding frame 26. After top roller 27A is positioned into holding frame 26 on either side of the top roller, a simple cotter pin or the like is all that is needed to hold the top roller 27 in position.

FIG. 5 shows a section taken along Section B--B of FIG. 2 of the novel extensible continuous haulage apparatus and method of the present invention.

Referring now to FIG. 5, a section B--B taken from FIG. 2 is shown. Side rail 22 is shown to be press fit onto male connecting pin 28 adapted to be affixed to or to be a part of holding frame 26. Rail 22 is press fit onto pin 28, and the structure is held together by belt tension of the endless conveyor belt.

Side rails 22 are adapted to be capable of carrying a mobile bridge. The wheels (not shown) of the mobile bridge or other dolly or carriage would run on the top side of rail 22 or 24. The rails 22 and 24 are provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24.

The novel mining extensible continuous haulage apparatus and method of the present invention incorporate side rails 22 and 24 which are press fit in attachment to the holding frames 26. In a preferred embodiment, the novel mining extensible continuous haulage apparatus and method of the present invention incorporate a press fit attachment to provide a bolt-free attachment of side rails 22 and 24 to frame stand 26. The floor-mounted belt stand preferably is rigidly connected bolt-free to an adjacent floor-mounted belt stand.

FIG. 6 shows a perspective view of the novel extensible continuous haulage apparatus and method of the present invention.

Referring now to FIG. 6, conveyor 120 includes side rails 122 and 124 interconnected with holding frame 126 for holding top roller 127 and bottom belt return support 129. Holding frames 126 are floor-supported frame members.

Rails 122 and 124 slide onto pins attached to holding frame 126 as indicated by pins 128 for connecting rail 122 as shown in FIG. 6. Rail continuity insert 123 is positioned between ends of rail 122 to provide and maintain a continuity in the rail top surface for wheels (not shown) of a mobile bridge or other dolly or carriage to run on the top side of rail 122 or 124.

The rails 122 and 124 are provided with equal angular sides and side dimensions so that rails 122 and 124 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 122 and 124. By way of example, the rails can be round or square. In the case when rails 122 and 124 are square and provided with equal angular sides and side dimensions so that rails 122 and 124 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 122 and 124, an alignment brace 130 is provided to align the rail surfaces. Alignment brace 130 also provides higher rigidity to holding frame 126 and facilitates the prevention of snaking of the extensible conveyor system of the present invention.

FIG. 7 shows a perspective view of a specific embodiment of the roller combination insert for the novel extensible continuous haulage apparatus and method of the present invention.

Referring now to FIG. 7, roller combination insert 127 has central or middle portion 127a and lateral, end portions 127b. The insert is supported by roller combination insert support 127c. Rollers 131 and 133 are positioned on either ends of roller combination insert support 127c. Rollers 135, 137, and 139 are held on support flanges 141 welded onto roller combination insert support 127c. Pins 143 hold rollers 135, 137, and 139 on support flanges 141. Holding frame connecting flanges 125 are welded onto the outside lateral ends of roller combination insert support 127c for connecting roller combination insert support 127c to holding frame 126.

The roller combination insert in the extensible haulage system of the present invention allows the mine operator to use motors and conveyor drive devices having significantly less power. The roller combination insert reduces the conveyor drive motor requirements in size and amperage. The roller combination insert also permits for longer runs of conveyor between conveyor drive motors.

The roller combination insert in the extensible haulage system of the present invention allows the mine operator to use larger conveyors and heavier belts, thereby to convey more massive amounts of mined material.

FIG. 8 shows the novel mining conveyor apparatus as viewed along Section A--A of FIG. 6.

Referring now to FIG. 8, top roller 127 is shown having a substantially horizontally disposed middle section 127a and upwardly turned end sections 127b to form a troughing or cupping angle greater than about 15° of troughing/cupping and, preferably, greater than about 20°. Most preferably, horizontally disposed middle section 127a and upwardly turned end sections 127b form a troughing or cupping angle greater than about 27°.

Side rails 122 and 124 on opposite sides of the conveyor frame apparatus are shown having substantially equal angular sides and side dimensions so that the rails can be rotated to change the top surface as will be described in detail hereinbelow.

Bottom belt return support 129 preferably of a lightweight abrasion-resistant material supports the belt return for the endless belt conveyor system.

The wearing surface of top roller 127 can be replaced in the mine by removing top roller 127. A new lightweight top roller insert 127A can be fitted into and fastened into position by suitable fastener for connecting holding frame connecting flanges 125 to holding frame 126 to install the new top roller 127A quickly in place in the mine.

The top roller 127 is formed such that it can be installed with any side (127b) on either of the holding stands 126. The top roller 127 thereby is interchangeable without regard to which side must be installed on a particular side of the holding support stand.

Top roller 127A is shown as it is to be built into the holding frame 126. After top roller 127A is positioned into holding frame 126 on either side of the top roller, a simple cotter pin or the like is all that is needed to hold the top roller 127 in position.

FIG. 9 shows a section taken along Section B--B of FIG. 6 of the novel extensible continuous haulage apparatus and method of the present invention.

Referring now to FIG. 9, a section B--B taken from FIG. 6 is shown. Side rail 122 is shown to be press fit onto male connecting pin 128 adapted to be affixed to or to be a part of holding frame 126. Rail 122 is press fit onto pin 128, and the structure is held together by belt tension of the endless conveyor belt.

Side rails 122 are adapted to be capable of carrying a mobile bridge. The wheels (not shown) of the mobile bridge or other dolly or carriage would run on the top side of rail 122 or 124. The rails 122 and 124 are provided with equal angular sides and side dimensions so that rails 122 and 124 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 122 and 124.

The novel mining extensible continuous haulage apparatus and method of the present invention incorporate side rails 122 and 124 which are press fit in attachment to the holding frames 126. In a preferred embodiment, the novel mining extensible continuous haulage apparatus and method of the present invention incorporate a press fit attachment to provide a bolt-free attachment of side rails 122 and 124 to frame stand 126. The floor-mounted belt stand preferably is rigidly connected bolt-free to an adjacent floor-mounted belt stand.

The novel mining extensible continuous haulage apparatus and method of the present invention provide quick and nimble extendible and retractable construction of the belt stands in the mine to facilitate room advancement. As the continuous miner extends into the face, the novel mining extensible continuous haulage and method of the present invention can extend with it.

The extensible continuous haulage apparatus of the present invention can provide larger widths used for more massive amounts of coal to be conveyed, e.g., coal sheered from a long wall miner. The extensible continuous haulage apparatus of the present invention can provide for larger conveyor widths, e.g., a 42 inches wide conveyor, a 48 inches wide conveyor, or even larger. The extensible continuous haulage apparatus of the present invention also can provide for standard conveyor widths of 30 inches, 36 inches, or 42 inches, or other widths, e.g., non-standard widths, as required in a particular application so that the capacity and/or length of the extensible continuous haulage can be increased.

Also for larger conveyor widths, e.g., the 42 inches wide conveyor, box tubing preferably is used in place of a beam for the roller combination insert support 127c to provide more strength. It has been found that a 2 inches square box tubing works well for a 36 inches wide conveyor, and a 21/2 inches square box tubing works well for a 42 inches wide conveyor. We have found that the 21/2 inches square box tubing provides double the strength of the 2 inches square box tubing, e.g., 1.1 kip (1,100 load capacity) for the 2 inches square box tubing compared to 2.1 kip (2,100 load capacity) for the 21/2 inches square box tubing.

We have found that the larger box tubing also works well for the larger bridges more frequently being used today behind the continuous miners.

The conveyor length in the extensible continuous haulage system of the present invention can be 750 feet to 1,000 feet or longer and will be limited only by mining regulations.

The floor-mounted holding frames are positioned to be interconnected with press-fit attachment of side rails to the frame members. No bolts are needed. The novel mining extensible continuous haulage and apparatus of the present invention provide a superior advantage over conventional conveyor apparatus in that bolts are eliminated.

Workers who have toiled in the dark, confined spaces and constraints of the mine, particularly in low coal, often times working in muck and mire, will appreciate the feature of eliminating these bolts. Bolts typically are lost, dropped, or at least are difficult to thread and bolt up. Moreover, bolts become gunked up in the muck and mire in a mine. The gunked-up bolts are difficult to thread or install.

Not only is it easier physically to build and disassemble the novel extensible continuous haulage of the present invention, but also these conventional connecting bolts are eliminated for a substantial cost savings because these conventional connecting bolts are not cheap, but rather have a material cost on the order of about three dollars each to replace (1995 dollars) irrespective of the labor intensive cost of installation.

The novel mining extensible continuous haulage and apparatus of the present invention provide an extensible conveyor apparatus for a continuous haulage system including a continuous conveyor belt for carrying coal or ore discharged from a continuous miner, a top roller for supporting the coal-carrying or ore-carrying continuous conveyor belt, a bottom belt return, and a holding frame for holding the top roller.

The holding frame is provided by a plurality of floor-supported frame members held in position by belt tension, the holding frame being capable of rapid and nimble extendable, retractable construction in the mine. The conveyor belt itself holds the floor-mounted holding structure together in tension. The conveyor belt is held taut by jack belt tensioning, and the belt tension on the floor-mounted holding frame.

The top roller preferably is provided by a combination of rollers having a low coefficient of friction. The top roller combination preferably is composed of ball-bearing rollers.

The conveyor belt and frame combination of the present invention provides a low profile continuous haulage system for carrying coal from low coal seams, e.g., such as less than about 48 inches in vertical height. The low coal seams make it extremely difficult for physical activity in the confining spaces and constraints of the underground mine. Every physical effort is magnified manyfold in difficulty level by the confining spaces of the low coal.

The side rails, e.g., side rails 22, 122 and 24, 124 as shown in the drawings, are provided by lightweight rails. In one embodiment, the lightweight rails are provided by round or square tubular steel material and weigh less than about five pounds per foot and preferably less than about four pounds per foot, e.g., such as less than about 25 pounds, preferably less than 20 pounds, over about five feet of length. The lightweight rails of the present invention are compared to rails weighing as much as 100 to 150 pounds and more over about five feet of length in conventional conveyor systems.

The lightweight rails are adapted to be placed into press-fit attachment with protruding pins horizontally fixed to the holding frame members. In this way, the side rails include tubular rails acting as pin-receiving connecting members for receiving the protruding pins horizontally fixed on the frame members. The four-sided tubular rails can be quickly rotated to change the top wear surface and extend the service life of the rails for carrying the mobile bridges of the continuous haulage system of the present invention.

In the extensible continuous haulage system of the present invention, the conveyor belt itself holds the floor-mounted holding structure together in tension. The conveyor belt is held taut by jack belt tensioning and the belt tension on the floor-mounted holding frame. In one aspect of a preferred embodiment of the extensible continuous haulage system of the present invention, side rail 22 or 122 is shown to be press fit onto male connecting pin 28 or 128 adapted to be affixed to or to be a part of holding frame 26 or 126. Rail 22 or 122 is press fit onto pin 28 or 128, and the structure is held together by belt tension of the endless conveyor belt.

The importance of the structure held together by belt tension of the endless conveyor belt in the extensible continuous haulage system of the present invention is highlighted by side rails 22, 24 or 122, 124 capable of carrying a mobile bridge. The wheels of the mobile bridge or other dolly or carriage run on the top side of rail 22, 24 or 122, 124.

The importance of the structure held together by belt tension of the endless conveyor belt in the extensible continuous haulage system of the present invention is further highlighted by side rails 22, 24 or 122, 124 provided with equal angular sides and side dimensions so that rails 22, 24 or 122, 124 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22, 24 or 122, 124. The extensible continuous haulage system of the present invention provides rails for connecting and holding adjacent frame members in position by press-fit attachment of the rails to the frame members, wherein the rails are quickly rotatable to change the top wear surface.

The elements of the extensible continuous haulage system of the present invention provide an extensible conveyor apparatus for a continuous haulage system which can operate or perform effectively and efficiently in a continuous haulage system. Conventional conveyors do not work with continuous haulage systems or run continuous haulage because their conveyors do not form a track needed for the mobile bridge units extending from and attached to the continuous mining machine to tram or travel on to form the continuous haulage system.

The extensible continuous haulage system of the present invention provides a holding frame for holding the top roller capable of rapid and nimble extendable, retractable construction in the mine.

The quick interchangeability (in the mine) feature of the present invention eliminates the need to handle, remove, and reinstall rollers which must be removed to a fabrication shop located outside the mine where the roller is welded into place on the frame members as is required in conventional conveyor systems. The roller insert of the present invention, however, can be rebuilt and retrofitted to provide quick interchangeability directly in the mine.

The top roller is formed such that it can be installed with any side, 27b, on either of the holding stands. The top roller thereby is interchangeable without regard to which side must be installed on a particular side of the holding support stand.

The novel mining extensible continuous haulage apparatus and method of the present invention are capable of providing a low profile, lightweight, continuous conveyor apparatus which is quickly extendable, retractable, and moveable in a low seam coal mine for continuous haulage room advancement. The present invention includes a continuous belt, a top roller insert, preferably having a low coefficient of friction and capable of supporting the continuous belt as it carries coal from the discharge of a continuous miner and for forming a troughing or cupping angle greater than about 25°. The present invention further includes a floor-mounted holding stand less than about ten inches in overall vertical height for holding the top roller and a bottom roller belt return in position such that the holding stand is capable of and provides quick and nimble extendable or retractable construction in a low seam coal mine to facilitate rapid room advancement at a minimum of continuous miner production downtime.

The present invention further includes lightweight rails weighing less than about five pounds per foot, preferably less than about four pounds per foot, of length interconnecting the holding stand without bolts, the rails being capable of carrying a mobile bridge of the continuous miner. The lightweight rails further are quickly rotatable in the low seam coal mine to change wear surfaces on the rail to extend the life of the bridge-carrying rail.

We have found that the extensible continuous haulage system of the present invention permit a mining crew to "belt-up" in as short a time as twenty (20) minutes, for example. This short time is surprising for mining operations today, particularly in low seam coal mining. This quick extensible capability permits a crew to "belt-up" as many as two and three times per shift, if needed. It has been found that, upon an inspection and analysis of production log sheets for a particular shift or production period, the mining operation can be conducted without an apparent downtime for extending or retracting the novel extensible continuous haulage system of the present invention.

We have found empirically that the roller combination insert in the extensible haulage system of the present invention allows the mine operator to use motors and conveyor drive devices having significantly less power. The roller combination insert reduces the conveyor drive motor requirements in size and amperage. The roller combination insert also permits for longer runs of conveyor between conveyor drive motors.

We also have found that the roller combination insert in the extensible haulage system of the present invention allows the mine operator to use larger conveyors and heavier belts, thereby to convey more massive amounts of mined material.

The novel extensible continuous haulage apparatus and method of the present invention accordingly are significantly superior over conventional conveyor apparatus and methods which typically result in significantly less production during a shift in which the conveyor must be extended or retracted.

The apparatus and method of the present invention are not intended to be limited to the descriptions of specific embodiments hereinabove, but rather the apparatus and method of the present invention should be viewed in terms of the claims which follow and equivalents thereof. 

What is claimed is:
 1. An extensible conveyor apparatus for a continuous haulage system, comprising:a. a continuous conveyor belt for carrying mined material discharged from a continuous miner in an underground mine; b. a top roller for supporting said continuous conveyor belt; c. a bottom belt return for supporting said continuous conveyor belt on its return cycle; d. a holding frame for holding said top roller, said holding frame comprising a plurality of floor-supported frame members held in position by belt tension; e. rails for connecting and holding adjacent frame members in position by press-fit attachment of said rails to said frame members; f. pins attached to said holding frame for bolt-free press-fit attachment of said rails to said frame members; and g. a rail continuity insert positioned between rail ends to provide and maintain a continuity in the rail top surface for wheels of a mobile bridge or other dolly or carriage to run on the top side of said rails, wherein said rails are rotatable to change the top wear surface.
 2. A conveyor apparatus as set forth in claim 1, further comprising:h. an alignment brace for aligning the rail surfaces.
 3. A conveyor apparatus as set forth in claim 1, wherein said rails comprise round tubular rails acting as pin-receiving connecting members for receiving said pins protruding horizontally fixed on said frame members.
 4. A conveyor apparatus as set forth in claim 2, wherein said top roller provides a large angle of troughing/cupping greater than about 20 degrees of troughing/cupping in said coal-carrying continuous conveyor belt.
 5. A conveyor apparatus as set forth in claim 4, wherein said top roller has a low coefficient of friction.
 6. A conveyor apparatus as set forth in claim 5, wherein said top roller is comprised of a combination of rollers having a low coefficient of friction.
 7. A conveyor apparatus as set forth in claim 6, wherein said top roller is comprised of a combination of rollers connected to the center shaft supporting ball bearing rollers.
 8. A conveyor apparatus as set forth in claim 7, wherein said conveyor belt and frame combination comprises a low profile continuous haulage system for carrying coal from low coal seams less than about 48 inches in vertical height.
 9. A conveyor apparatus as set forth in claim 8, wherein said rails comprise lightweight rails weighing less than about 5 pounds per foot of length.
 10. A conveyor apparatus as set forth in claim 9, wherein said press-fit attachment comprises a bolt-free attachment of said rails to a frame stand.
 11. A conveyor apparatus as set forth in claim 10, wherein said top roller comprises a lightweight replaceable roller insert comprised of a combination of rollers and is quickly interchangeable in the mine.
 12. A method of continuously hauling coal or ore in a mine, comprising:a. receiving mined material from a continuous miner in an underground mine; b. conveying said mined material on a continuous belt; c. supporting said continuous belt by a floor-mounted belt stand rigidly connected bolt-free to an adjacent floor-mounted belt stand and held by tension of said continuous belt on said stands; d. providing a roller combination means for supporting said continuous belt; and e. providing rotatable rails for wheels of a mobile bridge or other dolly or carriage to run on the top side of said rails, wherein said rails are rotatable to change the top wear surface.
 13. A method as set forth in claim 12, wherein said wheeled-frame vehicle comprises a mobile bridge attached to said continuous miner.
 14. A method as set forth in claim 13, comprising providing said roller for supporting said continuous belt by said floor-mounted belt stand at a low profile vertical height to all components of the combination of elements, thereby providing a continuous haulage of mined material from the mine in low vertical seams of coal or ore less than about 48 inches.
 15. A low profile, lightweight, continuous conveyor apparatus quickly extendable, retractable, and movable in a low seam coal mine for continuous haulage room advancement, comprising:a. a continuous belt; b. a top roller insert, comprising a roller combination for supporting said continuous belt as it carries coal from the discharge of a continuous miner and for forming a troughing/cupping angle greater than about 20 degrees; c. a bottom slider belt return; d. a floor-mounted holding stand less than about ten inches in overall vertical height for holding said top roller insert and said bottom slider belt return in position, wherein said holding stand is capable of quick and nimble extendable or retractable construction in said low seam coal mine to facilitate rapid room advancement at a minimum of continuous miner production downtime; and e. lightweight rails weighing less than about 5 pounds per foot of length interconnecting said holding stand without bolts, said rails capable of carrying a mobile bridge of said continuous miner and quickly rotatable in said low seam coal mine to change wear surfaces on said rail to extend the life of the bridge-carrying rail. 